Legal claims defining the scope of protection. Each claim is shown in both the original legal language and a plain English translation.
1. A system for simulating welding activity, comprising: a welding tool for a simulated welding operation; a spatial tracking unit having at least one sensor, which detects movement and orientation of said welding tool during said simulated welding operation; a welding coupon; a processor based sub-system having a central processing unit, where said processor based sub-system is operatively coupled to said spatial tracking unit and receives information from said spatial tracking unit related to said movement and orientation of said welding tool during said simulated welding operation; a user input device coupled to said processor based sub-system, where said user input device allows selection of a first training mode and a second training mode; and a helmet having a first display device operatively coupled to said processor based subsystem which displays said simulated welding operation; wherein during said selected simulated welding operation, said processor based subsystem models a simulated welding surface for said welding coupon and displays said simulated welding surface on said first display device; wherein during said selected simulated welding operation, said processor based subsystem models a simulated weld puddle having real-time molten metal fluidity and real-time heat dissipation characteristics based on said movement and orientation of said welding tool during said simulated welding operation; wherein said processor based subsystem models a simulated weld bead based on a simulation of a solidification of said simulated weld puddle from a molten state to a solid state; wherein said first display device displays each of said simulated welding surface, said simulated weld puddle, said simulated weld bead, and said welding tool during said simulated welding operation; wherein during said first training mode said first display device displays a visual signal for a welding parameter during said simulated welding operation, where said visual signal is based on a deviation between a determined value for said welding parameter and a desired value for said welding parameter, and during said second training mode said visual signal is not displayed during said simulated welding operation, and wherein said determined value for said welding parameter is determined by said processor based subsystem based on said movement and orientation of said welding tool.
A welding simulation system includes a welding tool, a spatial tracker that detects the tool's movement and orientation, a simulated welding coupon, and a processor. The processor receives tracking data and simulates a welding surface on a helmet-mounted display. The system models a weld puddle with realistic molten metal flow and heat dissipation based on the tool's movement. It then simulates the weld puddle solidifying into a weld bead, which is also displayed. Two training modes are available. In the first mode, visual feedback on welding parameters (e.g., speed, angle, distance) is provided if the user deviates from desired values. In the second mode, this feedback is disabled, allowing the user to practice without assistance. The parameter values are calculated based on the tool's movement and orientation.
2. The system of claim 1 , wherein said tracking unit utilizes an optical sensor which is mounted on said helmet to optically track said welding tool.
The welding simulation system described previously uses an optical sensor mounted on the helmet as part of the spatial tracking unit. This sensor optically tracks the welding tool's position and orientation, providing data to the system's processor for simulating the welding process. The use of an optical sensor allows for real-time tracking of the welding tool during the simulation.
3. The system of claim 1 , further comprising an audio speaker which provides simulated welding sounds in real-time with the simulated welding operation, and where said audio speaker is disposed in said helmet.
The welding simulation system described previously includes an audio speaker integrated into the helmet. This speaker provides real-time simulated welding sounds that are synchronized with the virtual welding operation, such as the sound of the arc or metal being deposited. This enhances the realism of the simulation.
4. The system of claim 1 , further comprising a second display device coupled to said processor based subsystem, where said processor based subsystem generates a plurality of simulated welding parameters based on said movement and orientation of said welding tool and wherein said second display device displays said plurality of simulated welding parameters during said simulated welding operation, and wherein at least one of said plurality of simulated welding parameters is displayed in graphical form in real time during said simulated welding operation.
The welding simulation system described previously features a second display device connected to the processor. This display shows various simulated welding parameters (e.g., voltage, current, travel speed) based on the welding tool's movement and orientation. At least one of these parameters is displayed graphically in real-time, providing the user with immediate feedback on their technique.
5. The system of claim 1 , further comprising a second display device coupled to said processor based subsystem which displays a difference between said determined value for said welding parameter and said desired value for said welding parameter during said simulated welding operation.
The welding simulation system described previously uses a second display device to show the difference between the determined value of a welding parameter (calculated from the tool's movement) and the desired value for that parameter. This numerical difference provides precise feedback on how far the user is deviating from the ideal welding conditions.
6. The system of claim 1 , wherein said processor based subsystem further compares said determined value for said welding parameter to a tolerance window defined by limits around a setpoint for said welding parameter, and wherein said processor based subsystem displays said comparison on a second display device.
In the welding simulation system described previously, the processor compares the calculated welding parameter value to a tolerance window, which defines acceptable limits around a setpoint for that parameter. This comparison is displayed on a second display device, informing the user whether their technique is within acceptable bounds.
7. The system of claim 1 , wherein said processor based subsystem generates a score for said welding parameter based on said deviation.
In the welding simulation system described previously, the processor calculates a score for each welding parameter based on how much the user deviates from the desired value. This score provides a quantitative assessment of the user's performance.
8. The system of claim 1 , wherein said processor based subsystem determines a presence of a discontinuity within said simulated weld bead, where said discontinuity is a presence of at least one of spatter and porosity, and wherein said first display device displays said discontinuity during said simulated welding operation, in real time.
In the welding simulation system described previously, the processor detects discontinuities within the simulated weld bead, such as spatter or porosity. If any of these flaws are detected, they are displayed on the helmet-mounted display in real-time, allowing the user to immediately see the effects of their actions.
9. The system of claim 1 , wherein said processor based subsystem generates and displays on said first display device at least one welding effect, which can be any one of simulated welding sparks, simulated welding spatter, simulated arc glow and simulated porosity during said simulated welding operation, and where said at least one welding effect is displayed, in real time, based on said movement and orientation of said welding tool.
In the welding simulation system described previously, the system generates and displays welding effects on the helmet-mounted display. These effects can include simulated sparks, spatter, arc glow, and porosity. These effects are displayed in real-time and are based on the welding tool's movement and orientation, enhancing the realism of the simulation.
10. The system of claim 1 , wherein said simulation of said solidification from said molten state to said solid state of said weld puddle is based on a cooling threshold value for said simulated weld puddle.
In the welding simulation system described previously, the simulated solidification of the weld puddle is based on a cooling threshold value. When the simulated weld puddle's temperature drops below this threshold, it begins to solidify into the weld bead.
11. The system of claim 1 , wherein said first display device displays a weld bead wake characteristic during creation of said simulated weld bead, where said wake characteristic is generated based on a real time fluidity-to-solidification transition of said simulated weld puddle as said simulated weld puddle is moved.
In the welding simulation system described previously, the helmet-mounted display shows a "wake characteristic" of the weld bead during its creation. This wake reflects the real-time transition of the simulated weld puddle from a fluid to a solid state as the welding tool moves, indicating how quickly the metal is solidifying behind the tool.
12. A system for simulating welding activity, comprising: a welding tool for a simulated welding operation; a spatial tracking unit having at least one optical sensor, which detects movement and orientation of said welding tool during said simulated welding operation; a welding coupon; a simulated welding console comprising a processor based sub-system with a central processing unit, where said processor based sub-system is operatively coupled to said spatial tracking unit and receives information from said spatial tracking unit related to said movement and orientation of said welding tool during said simulated welding operation; a user input device coupled to said processor based sub-system, where said user input device allows selection of a first training mode and a second training mode; and a helmet having a first display device operatively coupled to said processor based subsystem which displays said simulated welding operation, and where said helmet comprises said at least one optical sensor and an audio speaker which provides simulated welding sounds during said simulated welding operation; wherein during said selected simulated welding operation, said processor based subsystem models a simulated welding surface for said welding coupon and displays said simulated welding surface on said first display device; wherein during said selected simulated welding operation, said processor based subsystem models a simulated weld puddle having real-time molten metal fluidity and real-time heat dissipation characteristics based on said movement and orientation of said welding tool during said simulated welding operation; wherein said processor based subsystem models a simulated weld bead based on a simulation of a solidification of said simulated weld puddle from a molten state to a solid state; wherein said first display device displays each of said simulated welding surface, said simulated weld puddle, said simulated weld bead, and said welding tool during said simulated welding operation; wherein during said first training mode said first display device displays a plurality of visual cues during said simulated welding operation, each of which corresponding to a distinct welding parameter, where each of said visual cues is based on a determined deviation between a determined value for each said distinct welding parameter and a desired value for each said distinct welding parameter, respectively, and during said second training mode said plurality of visual cues are not displayed during said simulated welding operation, and wherein said determined value for each said distinct welding parameter is respectively determined by said processor based subsystem based on said movement and orientation of said welding tool.
A welding simulation system includes a welding tool, a spatial tracker with an optical sensor for detecting the tool's movement, a simulated welding coupon, a console with a processor, a user input device for selecting training modes, and a helmet with a display. The helmet houses the optical sensor and an audio speaker for simulated welding sounds. The processor models the welding surface, weld puddle fluidity/heat dissipation, and weld bead solidification. The helmet display shows the welding surface, puddle, bead, and tool. In the first training mode, visual cues linked to welding parameters show deviations from desired values. These cues are absent in the second mode. Parameter values are based on the tool's motion.
13. The system of claim 12 , further comprising a second display device coupled to said processor based subsystem, where said second display device displays said determined value for each said distinct welding parameter during said simulated welding operation.
The welding simulation system described previously uses a second display device to show the determined value for each distinct welding parameter during the simulated welding operation. This allows the user to see the specific numerical values (e.g. travel speed, voltage) being calculated by the system.
14. The system of claim 12 , further comprising a second display device coupled to said processor based subsystem which displays said determined deviation for each said distinct welding parameter, respectively.
The welding simulation system described previously uses a second display device to display the determined deviation for each distinct welding parameter respectively. This display presents the difference between the desired and actual values for each parameter, offering direct insight into errors.
15. The system of claim 12 , wherein said processor based subsystem further compares said determined value for each said distinct welding parameter to a tolerance window defined by limits around a setpoint for said distinct welding parameter, respectively, and wherein said processor based subsystem displays each said comparison on a second display device.
The welding simulation system described previously compares the determined value for each welding parameter to a tolerance window and displays each comparison on a second display. This enables a clearer understanding of whether parameters are within acceptable ranges.
16. The system of claim 12 , wherein said processor based subsystem determines a presence of a discontinuity within said simulated weld bead, where said discontinuity is a presence of at least one of spatter and porosity, and wherein said first display device displays said discontinuity during said simulated welding operation, in real time.
The welding simulation system described previously detects discontinuities such as spatter and porosity within the simulated weld bead. The helmet's display shows these discontinuities in real time, allowing the user to see and correct issues immediately.
17. The system of claim 12 , wherein said processor based subsystem generates and displays on said first display device at least one welding effect, which can be any one of simulated welding sparks, simulated welding spatter, simulated arc glow and simulated porosity during said simulated welding operation, and where said at least one welding effect is displayed, in real time, based on said movement and orientation of said welding tool.
The welding simulation system described previously generates and displays welding effects like sparks, spatter, arc glow and porosity on the helmet display. These effects appear in real time, based on the movement of the welding tool, adding realism to the simulation.
18. The system of claim 12 , wherein said simulation of said solidification from said molten state to said solid state of said weld puddle is based on a cooling threshold value for said simulated weld puddle.
In the welding simulation system described previously, the solidification of the molten weld puddle is simulated based on a cooling threshold value. The puddle solidifies when its temperature drops below this threshold.
19. The system of claim 12 , wherein said first display device displays a weld bead wake characteristic during creation of said simulated weld bead, where said wake characteristic is generated based on a real time fluidity-to-solidification transition of said simulated weld puddle as said simulated weld puddle is moved.
In the welding simulation system described previously, the helmet-mounted display shows the wake characteristics of the weld bead, generated from the real-time fluidity-to-solidification transition as the puddle moves.
20. A system for simulating welding activity, comprising: a welding tool for a simulated welding operation; a spatial tracking unit having at least one sensor, which detects movement and orientation of said welding tool during said simulated welding operation; a welding coupon; a processor based sub-system having a central processing unit, where said processor based sub-system is operatively coupled to said spatial tracking unit and receives information from said spatial tracking unit related to said movement and orientation of said welding tool during said simulated welding operation; a user input device coupled to said processor based sub-system, where said user input device allows selection of a first training mode and a second training mode; a simulated welding console comprising said processor based sub-system, said user input device, and a second display device which displays said simulated welding operation, in real time; and a helmet having a first display device operatively coupled to said processor based subsystem which displays said simulated welding operation, said helmet comprising said at least one sensor and an audio speaker to provide simulated welding sounds during said simulated welding operation; wherein during said selected simulated welding operation, said processor based subsystem models a simulated welding surface for said welding coupon and displays said simulated welding surface on said first display device; wherein during said selected simulated welding operation, said processor based subsystem models a simulated weld puddle having real-time molten metal fluidity and real-time heat dissipation characteristics based on said movement and orientation of said welding tool during said simulated welding operation; wherein said processor based subsystem models a simulated weld bead based on a simulation of a solidification of said simulated weld puddle from a molten state to a solid state; wherein said first display device displays each of said simulated welding surface, said simulated weld puddle, said simulated weld bead, and said welding tool during said simulated welding operation; wherein during said first training mode said first display device displays a visual cue for a welding parameter during said simulated welding operation, where said visual cue is based on a determined deviation between a determined value for said welding parameter and a desired value for said welding parameter, and during said second training mode said visual cue is not displayed during said simulated welding operation, and wherein said determined value for said welding parameter is determined by said processor based subsystem based on said movement and orientation of said welding tool.
A welding simulation system comprises a welding tool, spatial tracker, simulated welding coupon, a processor-based system, a user input, a simulated welding console with a second display, and a helmet with a first display and audio speaker. The spatial tracker and audio speaker are incorporated into the helmet. The processor simulates the welding surface and a weld puddle with real-time fluidity and heat dissipation characteristics based on welding tool movement. The system models the solidification of the puddle into a weld bead. The helmet's first display shows the welding surface, puddle, bead, and tool. In the first training mode, it displays a visual cue based on deviation from desired parameters. This cue is absent in the second mode.
21. A method for simulating welding activity, comprising: detecting movement and orientation of a welding tool using at least one sensor during a simulated welding operation; receiving information related to said movement and orientation of said welding tool during said simulated welding operation; allowing selection of a first training mode and a second training mode; displaying, on a first display device disposed in a helmet, said simulated welding operation; modeling a simulated welding surface for a welding coupon during said selected simulated welding operation; displaying said simulated welding surface on said first display device; modeling a simulated weld puddle having real-time molten metal fluidity and real-time heat dissipation characteristics based on said movement and orientation of said welding tool, during said simulated welding operation; modeling a simulated weld bead based on a simulation of a solidification of said simulated weld puddle from a molten state to a solid state; displaying, on said first display device, each of said simulated welding surface, said simulated weld puddle, said simulated weld bead, and said welding tool during said simulated welding operation; and displaying during said first training mode, on said first display device, a visual signal for a welding parameter during said simulated welding operation, where said visual signal is based on a deviation between a determined value for said welding parameter and a desired value for said welding parameter, wherein during said second training mode said visual signal is not displayed during said simulated welding operation, and wherein said determined value for said welding parameter is determined based on said movement and orientation of said welding tool.
A method for simulating welding involves detecting the movement of a welding tool using sensors, receiving related information, and allowing selection of training modes. The simulated welding operation is shown on a helmet display. A welding surface is modeled and displayed. A weld puddle with realistic fluid and heat properties is modeled based on the tool movement, and its solidification into a weld bead is simulated. The surface, puddle, bead, and tool are displayed on the helmet display. In the first training mode, visual feedback on welding parameters is displayed based on deviations from desired values. This feedback is absent in the second mode.
22. The method of claim 21 , wherein said at least one sensor is an optical sensor which is mounted on said helmet to optically track said welding tool.
The welding simulation method described previously uses an optical sensor mounted on the helmet to track the welding tool's movement. This provides real-time position and orientation data.
23. The method of claim 21 , further comprising: simulating welding sounds in real-time with the simulated welding operation using an audio speaker disposed in said helmet.
The welding simulation method described previously includes simulating welding sounds in real-time using an audio speaker in the helmet.
24. The method of claim 21 , further comprising: generating a plurality of simulated welding parameters based on said movement and orientation of said welding tool; and displaying, on a second display device, said plurality of simulated welding parameters during said simulated welding operation, wherein at least one of said plurality of simulated welding parameters is displayed in graphical form in real time during said simulated welding operation.
The welding simulation method described previously involves generating simulated welding parameters based on the tool's movement and displaying these parameters on a second display device. At least one of these parameters is graphically displayed in real time.
25. The method of claim 21 , further comprising: displaying, on a second display device, a difference between said determined value for said welding parameter and said desired value for said welding parameter during said simulated welding operation.
The welding simulation method described previously includes displaying the difference between the calculated welding parameter value and the desired value on a second display device.
26. The method of claim 21 , further comprising: comparing said determined value for said welding parameter to a tolerance window defined by limits around a setpoint for said welding parameter; and displaying said comparison on a second display device.
The welding simulation method described previously involves comparing the calculated welding parameter value to a tolerance window and displaying this comparison on a second display.
27. The method of claim 21 , further comprising: generating a score for said welding parameter based on said deviation.
The welding simulation method described previously generates a score for a welding parameter based on deviation from the desired value.
28. The method of claim 21 , further comprising: determining a presence of a discontinuity within said simulated weld bead, where said discontinuity is a presence of at least one of spatter and porosity; and displaying, on said first display device, said discontinuity during said simulated welding operation, in real time.
The welding simulation method described previously detects discontinuities (spatter, porosity) within the simulated weld bead and displays these in real-time on the primary display.
29. The method of claim 21 , further comprising: generating and displaying on said first display device at least one welding effect, which can be any one of simulated welding sparks, simulated welding spatter, simulated arc glow and simulated porosity during said simulated welding operation, and where said at least one welding effect is displayed, in real time, based on said movement and orientation of said welding tool.
The welding simulation method described previously generates and displays welding effects such as sparks, spatter, arc glow and porosity, in real-time, based on the movement of the welding tool, enhancing visual feedback.
30. The method of claim 21 , wherein said simulation of said solidification from said molten state to said solid state of said weld puddle is based on a cooling threshold value for said simulated weld puddle.
In the welding simulation method described previously, the weld puddle's solidification is based on a cooling threshold value.
31. The method of claim 21 , wherein said first display device displays a weld bead wake characteristic during creation of said simulated weld bead, where said wake characteristic is generated based on a real time fluidity-to-solidification transition of said simulated weld puddle as said simulated weld puddle is moved.
In the welding simulation method described previously, a wake characteristic is displayed on the helmet display during weld bead creation, representing the real-time fluid-to-solid transition as the puddle moves.
32. A method for simulating welding activity, comprising: detecting movement and orientation of a welding tool using at least one sensor during a simulated welding operation; receiving information related to said movement and orientation of said welding tool during said simulated welding operation; allowing selection of a first training mode and a second training mode; displaying, on a first display device disposed in a helmet, said simulated welding operation, and where said helmet comprises said at least one optical sensor and an audio speaker which provides simulated welding sounds during said simulated welding operation; modeling a simulated welding surface for a welding coupon; displaying said simulated welding surface on said first display device; modeling a simulated weld puddle having real-time molten metal fluidity and real-time heat dissipation characteristics based on said movement and orientation of said welding tool during said simulated welding operation; modeling a simulated weld bead based on a simulation of a solidification of said simulated weld puddle from a molten state to a solid state; displaying, on said first display device, each of said simulated welding surface, said simulated weld puddle, said simulated weld bead, and said welding tool during said simulated welding operation; displaying during said first training mode, on said first display device, a plurality of visual cues during said simulated welding operation, each of which corresponding to a distinct welding parameter, where each of said visual cues is based on a determined deviation between a determined value for each said distinct welding parameter and a desired value for each said distinct welding parameter, respectively, wherein during said second training mode said plurality of visual cues are not displayed during said simulated welding operation, and wherein said determined value for each said distinct welding parameter is respectively determined based on said movement and orientation of said welding tool.
A method for simulating welding involves detecting the welding tool's movement with a sensor, receiving tracking data, and allowing selection of training modes. The simulated welding is shown on a helmet display with a sensor and audio. The method models a welding surface, weld puddle fluidity/heat, and bead solidification. The helmet display shows the welding surface, puddle, bead, and tool. In training mode one, visual cues linked to welding parameters indicate deviations from desired levels. These cues are turned off in training mode two.
33. The method of claim 32 , further comprising: displaying, on a second display device, said determined value for each said distinct welding parameter during said simulated welding operation.
In the welding simulation method described previously, the determined value for each distinct welding parameter is displayed on a second display device during the simulation.
34. The method of claim 32 , further comprising: displaying, on a second display device, said determined deviation for each said distinct welding parameter, respectively.
In the welding simulation method described previously, the determined deviation for each distinct welding parameter is displayed on a second display, showing differences between actual and desired values.
35. The method of claim 32 , further comprising: comparing said determined value for each said distinct welding parameter to a tolerance window defined by limits around a setpoint for said distinct welding parameter, respectively; and displaying each said comparison on a second display device.
In the welding simulation method described previously, the determined value for each distinct welding parameter is compared to a tolerance window and the comparison is displayed on a second display.
36. The method of claim 32 , further comprising: determining a presence of a discontinuity within said simulated weld bead, where said discontinuity is a presence of at least one of spatter and porosity, and wherein said first display device displays said discontinuity during said simulated welding operation, in real time.
In the welding simulation method described previously, discontinuities within the simulated weld bead, like spatter and porosity, are detected and shown on the helmet display in real time.
37. The method of claim 32 , further comprising: generating and displaying on said first display device at least one welding effect, which can be any one of simulated welding sparks, simulated welding spatter, simulated arc glow and simulated porosity during said simulated welding operation, and where said at least one welding effect is displayed, in real time, based on said movement and orientation of said welding tool.
In the welding simulation method described previously, welding effects (sparks, spatter, arc glow, porosity) are generated and displayed on the helmet's first display in real time, based on the movement of the tool.
38. The method of claim 32 , wherein said simulation of said solidification from said molten state to said solid state of said weld puddle is based on a cooling threshold value for said simulated weld puddle.
The welding simulation method described previously models the solidification of the weld puddle from liquid to solid based on a cooling threshold value.
39. The method of claim 32 , wherein said first display device displays a weld bead wake characteristic during creation of said simulated weld bead, where said wake characteristic is generated based on a real time fluidity-to-solidification transition of said simulated weld puddle as said simulated weld puddle is moved.
In the welding simulation method described previously, the helmet display presents a weld bead wake characteristic, reflecting the fluid-to-solid transition as the puddle moves and solidifies.
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October 3, 2017
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